Apparatus and method for an infrared pressure weld reservoir

ABSTRACT

A fluid reservoir for a vehicle comprises a first reservoir portion and a second reservoir portion, wherein the first and the second reservoir portions define a reservoir to retain fluid for a washer system. The first reservoir portion and the second reservoir portion are secured together using infrared welding.

CROSS REFERENCE TO RELATED APPLICATION

This application claims priority to U.S. Provisional Application No.62/062,320 filed on Oct. 10, 2014.

TECHNICAL FIELD

The present disclosure relates to fluid reservoirs and more particularlyto fluid reservoirs for automotive vehicle washer systems.

BACKGROUND

Vehicle washer systems require reservoirs to retain the fluid untilneeded. The required fluid reservoir size is increasing as more featureson vehicles need washing, e.g. rear windows, headlights, etc. However,vehicle packaging space is limited for such reservoirs. Typically,washer reservoirs are injection molded using thin wall or light weightstructure. The washer reservoirs then have to be welded. The currentwelding approach is a weld flange at 90 degree (perpendicular toreservoir walls). This creates a limited weld surface area and requiresa minimum proximity to other components with high thermal conditions,which takes up limited packaging space within a vehicle. However, adirect fracture point at the internal weld is created that can bebreached during freeze conditions, vibration testing, and from thermalshock.

The background description provided herein is for the purpose ofgenerally presenting the context of the disclosure. Work of thepresently named inventors, to the extent it is described in thisbackground section, as well as aspects of the description that may nototherwise qualify as prior art at the time of filing, are neitherexpressly nor impliedly admitted as prior art against the presentdisclosure.

SUMMARY

A fluid reservoir for a vehicle comprises a first reservoir portion anda second reservoir portion, wherein the first and the second reservoirportions define a reservoir to retain fluid for a washer system. Anoverlapping portion of the first reservoir portion and the secondreservoir portion is formed between them when the portions are securedtogether. The overlapping portion is a weld formed using an infraredweld apparatus.

A method of infrared welding a fluid reservoir for a vehicle comprisesplacing a first reservoir portion inside a first cavity defined by afirst weld portion and a second reservoir portion inside a second cavitydefined by a second weld portion. A first light array concentricallysurrounds the first reservoir portion and a second light array isconcentrically inside the second reservoir portion. The first weldposition and the second weld portion are heated using the first andsecond light array. Then the light arrays are moved away and the firstweld portion and the second weld portion are moved together until anoverlapping portion is formed by the first reservoir portion and thesecond reservoir portion. A pair of slides are placed to concentricallysurround the overlapping portion and pressurized air is applied to thereservoir to force the overlapping portion against the slides to securethe first reservoir portion and the second reservoir portion together atthe weld.

An infrared weld apparatus for a fluid reservoir comprises a first weldportion defining a first weld cavity to receive a first reservoirportion and a second weld portion defining a second weld cavity toreceive a second reservoir portion. A pair of slides concentricallysurround an overlapping portion of the first reservoir portion and thesecond reservoir portion, when the first reservoir portion, first weldportion, second reservoir portion and second weld portion are assembledtogether. A first light array is located concentrically surrounding theoverlapping portion and assembled inside the pair of slides and a secondlight array located concentrically inside the overlapping portion,parallel to the first light array. The first light array and secondlight array are configured to apply heat at the overlapping portion toweld the first reservoir portion to the second reservoir portion.

Further areas of applicability of the present disclosure will becomeapparent from the detailed description provided hereinafter. It shouldbe understood that the detailed description and specific examples, whileindicating the preferred embodiment of the disclosure, are intended forpurposes of illustration only and are not intended to limit the scope ofthe disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure will become more fully understood from thedetailed description and the accompanying drawings, wherein:

FIG. 1 is a schematic illustrations of a washer reservoir for a vehicleformed using an infrared pressure weld method; and

FIG. 2 is an enlarged schematic illustration of a front view of thewasher reservoir and welding components showing section line 3-3;

FIG. 3 is an enlarged schematic illustration of a cross-sectional viewof the washer reservoir and welding components along the section line3-3 of FIG. 2;

FIG. 3A is an enlarged schematic illustration of a cross-sectional viewof a section X the washer reservoir and welding components illustratinga weld zone;

FIG. 4 is an exploded schematic front view illustration of the washerreservoir and welding components of FIGS. 2-3 showing section line 5-5;and

FIG. 5 is an enlarged schematic illustration of a cross-sectional viewof the washer reservoir and welding components along the section line5-5 of FIG. 4; and

FIG. 6 is an enlarged schematic perspective illustration of the washerreservoir and welding components of FIGS. 4-5.

DETAILED DESCRIPTION

The following description is merely exemplary in nature and is in no wayintended to limit the disclosure, its application, or uses. For purposesof clarity, the same reference numbers will be used in the drawings toidentify similar elements. FIGS. 1-6 illustrate a washer reservoir 12for a vehicle. The reservoir 12 is intended for use in a washer systemfor a vehicle. However, the reservoir 12 can also be used for othertypes of applications. The washer reservoir 12 is formed by injectionmolding to for a first reservoir portion 14 and a second reservoirportion 16. The first reservoir portion 14 and the second reservoirportion 16 are partially nested together with an overlapping portion 18.The first reservoir portion 14 may define a fluid inlet 20. A fluidpassage 22 may connect to the fluid inlet 20. The fluid inlet 20 andfluid passage 22 may be used when the washer reservoir is in the vehicleto add fluid into the reservoir 12. During the welding process the fluidinlet 20 and fluid passage 22 can be used to introduce pressurized airinto the reservoir 12 as explained in further detail below.

Referring to FIGS. 1-6 the washer reservoir 12 is shown with a weldingapparatus 24. The welding apparatus 24 has a first weld portion 26 and asecond weld portion 28. The first weld portion 26 defines a first cavity30 corresponding to the shape of the first reservoir portion 14. Thesecond weld portion 28 defines a second cavity 32 corresponding to theshape of the second reservoir portion 26. During the weld process thefirst reservoir portion 14 and the second reservoir portion 16 arenested in the first weld portion 26 and second weld portion 28.

An aperture 34 in the first weld portion 26 accommodates the fluid inlet20, allowing air to pass through the fluid inlet 20 and fluid passage 22into the washer reservoir 12. An air nozzle 36 for the weld apparatus 24can apply pressurized air into the washer reservoir 12. The pressurizedair forces the first reservoir portion 14 and the second reservoirportion 16 outward again the first weld portion 26 and the second weldportion 28 to hold the reservoir 14, 16 during the weld process. The airnozzle 36 can be configured to match an opening into the air passage 22.

Additional fluid inlets 20 may be used to allow pressurized air into thewasher reservoir. For example, an aperture in the second portion 16,which is used to allow fluid to exit the reservoir 12 to the washersystem during use in the vehicle, may also be use to allow pressurizedair into the washer reservoir 12 during the weld process. Otherapertures may also be use to provide pressurized air during the weldprocess and then sealed or used for other purposes. Once skilled in theart would be able to determine the desired number of inlets 20 toprovide pressurized air during the weld process based upon the shape,size, and process for a particular washer reservoir 12 and weldapparatus 24.

The welding apparatus 24 also includes a pair of slides 38 which fitover the washer reservoir 12 at positions that correspond to theoverlapping portion 18. Once the first reservoir portion 14 an firstweld portion 26 are positioned together with the second reservoirportion 16 and the second weld portion 28 the overlapping portion 18 isformed. The overlapping portion 18 is the targeted weld zone.

During the weld process a first infrared light array 40 is placed tosurround the first reservoir portion 14 corresponding to what will bethe overlapping portion 18 of the first weld portion 26. A secondinfrared light array 42 is placed within the second reservoir portion 16and also corresponds to the location of the overlapping portion 18 ofthe second weld portion 28. Infrared light is applied by the firstinfrared light array 40 and the second infrared light array 42 to weldthe first reservoir portion 14 to the second reservoir portion 16 at theoverlapping area 18. The light array directs the heat to the desiredspecific weld zone(s).

The first and the second light arrays 40 and 42 are heated until theareas which will form the overlapping portion 18 have reached asufficient predetermined temperature. If necessary the first and thesecond light arrays 40 and 42 are then moved out of the way and thefirst weld portion 26 and the second weld portion 28 are moved togetherto form the overlapping portion 18. The second light array 42 is locatedinside the second reservoir portion 16 and will likely need to be movedout of the way in order for the first reservoir portion 14 and thesecond reservoir portion to be assembled together. Likewise, the secondlight array 40 will likely need to be moved out of the way in order forthe slides 38 to surround the overlapping portion 18.

From the outside, once assembled the pair of slides 38, are moved intoposition to surround the overlapping portion 18. The washer reservoir 12is filled with pressurized air, which forces the overlapping portion 18outward against the slides 38.

Using internal pressure and the moving nests 26, 28 the welding canoccur in a manner that is not typical possible using infrared or hotplate welding. This process requires both sides of the weld, i.e. upperportion 14 and lower portion 16 at the overlapping area 18, to bepressed together and held using the nests 26, 28 on both sides andpressurized air within. A perpendicular weld flange, i.e. first andsecond light arrays 40, 42, is used to provide access for the neededpressure. Placing the weld surface 18 in the manner proposed removes thefracture point, increases weld surface area creating a stronger weld,and allows greater flexibility to respond to thermal and dynamicconditions acting on the reservoir 12 when it is assembled in thevehicle.

Therefore, referring to FIGS. 1-6, a fluid reservoir 12 for a vehiclecomprises a first reservoir portion 14 and a second reservoir portion16, wherein the first and the second reservoir portions 14, 16 define areservoir 12 to retain fluid for a washer system. An overlapping portion18 of the first reservoir portion 14 and the second reservoir portion 16is formed between them when the portions 14, 16 are secured together.The overlapping portion is a weld 19 formed using an infrared weldapparatus 24.

The infrared weld apparatus 24 comprises a first nest 26 defining afirst weld cavity 30 to receive the first reservoir portion 14 and asecond nest 28 defining a second weld cavity 32 to receive the secondreservoir portion 16. A first light array 40 is located concentricallysurrounding the first reservoir portion 14 at the location that willbecome the overlapping portion 18 and a second light array 42 is locatedconcentrically inside the second reservoir portion 16 at the locationthat will become the overlapping portion 18, and parallel to the firstlight array 40.

The first and the second light arrays 40 and 42 are heated usinginfrared heat, until the areas which will form the overlapping portion18 have reached a sufficient predetermined temperature. The first andthe second light arrays 40 and 42 are then moved out of the way and thefirst nest 26 and the second nest 28 are moved together to form theoverlapping portion 18.

A pair of slides 38 are moved in place to concentrically surround theoverlapping portion 18 when the first reservoir portion 14, first weldportion 26, second reservoir portion 16 and second weld portion 28 areassembled together. Pressurized air is pumped into the fluid reservoir12 after the first reservoir portion 14, first weld portion 26, secondreservoir portion 16, second weld portion 28, and the slides 38 areassembled together. The first reservoir portion 14 defines a fluid inlet29 to receive the pressurized air when the fluid reservoir 12 isassembled in the weld apparatus 24 and to receive washer fluid when thefluid reservoir 12 is assembled in the vehicle.

A method of infrared welding a fluid reservoir 12 for a vehiclecomprises placing a first reservoir portion 14 inside a first cavity 30defined by a first weld portion 26 and a second reservoir portion 16inside a second cavity 32 defined by a second weld portion 28. A firstlight array 40 concentrically surrounds the first reservoir portion 14and a second light array 42 is concentrically inside the secondreservoir portion 16. The first light array 40 and the second lightarray 42 apply infrared heat to the first reservoir portion 14 and thesecond reservoir portion 16.

The first light array 40 and the second light array 42 are moved out ofthe way. The first weld portion 26 and the second weld portion 28 aremoved together until an overlapping portion 18 formed is formed by thefirst reservoir portion 14 and the second reservoir portion 16. A pairof slides 38 are placed to concentrically surround the overlappingportion 18 and the reservoir 12 is filled with pressurized air to weldthe first reservoir portion 16 to the second reservoir portion 18,forming the weld 19, wherein the first reservoir portion defines a fluidinlet to receive washer fluid when the fluid reservoir is assembled inthe vehicle.

The infrared weld apparatus 24 for welding a fluid reservoir 12comprises a first weld portion 26 defining a first weld cavity 30 toreceive a first reservoir portion 14 and a second weld portion 28defining a second weld cavity 32 to receive a second reservoir portion16. A first light array 40 is located concentrically surrounding theoverlapping portion 18 of the first reservoir portion 14 and a secondlight array 42 is located concentrically inside the overlapping portion18 of the second reservoir portion 16, parallel to the first light array40. The first light array 40 and second light array 42 are configured toapply heat at the overlapping portion 18. A pair of slides 38concentrically surround an overlapping portion 18 of the first reservoirportion 14 and the second reservoir portion 16, when the first reservoirportion 14, first weld portion 26, second reservoir portion 16 andsecond weld portion 28 are assembled together.

Pressurized air is pumped into the fluid reservoir 12 after the firstreservoir portion 14, first weld portion 26, second reservoir portion16, second weld portion 28, and the slides 38 are assembled together.

The first reservoir portion 14 also defines a fluid inlet 29 to receivethe pressurized air when the fluid reservoir 12 is assembled in the weldapparatus 24 and to receive washer fluid when the fluid reservoir 12 isassembled in the vehicle.

While the best modes for carrying out the invention have been describedin detail the true scope of the disclosure should not be so limited,since those familiar with the art to which this invention relates willrecognize various alternative designs and embodiments for practicing theinvention within the scope of the appended claims.

What is claimed is:
 1. A fluid reservoir for a washer system comprising:a first reservoir portion; a second reservoir portion, wherein the firstand the second reservoir portions define a reservoir to retain fluid fora washer system; and an overlapping portion of the first reservoirportion and the second reservoir portion, wherein the first reservoirportion is nested within the second reservoir portion within theoverlapping portion and a weld is formed within the overlapping portionbetween the first reservoir portion and the second reservoir portionusing an infrared weld, wherein each of the first reservoir portion andthe second reservoir portion include side walls that are disposedparallel to each other within the overlapping portion and the firstreservoir portion includes a flange extending from an exterior surfaceof a corresponding one of the side walls for setting a length of overlapbetween the side walls within the overlapping portion and the infraredweld is between the exterior surface of the first reservoir portion andan interior surface of the second reservoir portion within theoverlapping portion.
 2. The fluid reservoir of claim 1, wherein thefirst reservoir portion is nested within the second reservoir portionsuch that when pressurized air is pumped into the fluid reservoir afterthe first reservoir portion, is nested within the second reservoirportion prior to formation of the weld, the first reservoir portion ispushed radially outward against the second reservoir portion within theoverlapping portion.
 3. The fluid reservoir of claim 2, wherein thefirst reservoir portion defines a fluid inlet to receive the pressurizedair to push the first reservoir portion radially outward against thesecond reservoir portion prior to formation of the weld.
 4. The fluidreservoir of claim 1, wherein the first reservoir portion defines afluid inlet to receive washer fluid when the fluid reservoir isassembled in a vehicle.
 5. The fluid reservoir of claim 1, wherein theside walls are disposed parallel to each other within the overlappingregion and outside of the overlapping region.
 6. The fluid reservoir ofclaim 1, wherein the side walls of both the first reservoir portion andthe second reservoir portion within the overlapping portion and outsideof the overlapping portion extend in a common direction.
 7. The fluidreservoir of claim 1, wherein the flange extends perpendicular from theexterior surface of the corresponding side wall outside of theoverlapping portion.